# US 8,785,539 B2 · Siliceous-based polyurea compositions

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- Number: US 8,785,539 B2
- Document ID: US8785539B2
- Status: Granted
- Kind: B2
- Application number: 13/387,512
- Filed: 2010-07-07
- Published: 2012-07-26
- Granted: 2014-07-22
- Earliest claimed: 2009-07-30
- Assignees: Construction Research & Technology GmbH
- Applicants: Shane Oliver McDonnell; Christian Trieflinger; Werner Temme; Grzegorz Gomulka; Michael Melchart; Burkhard Walther
- Inventors: Shane Oliver McDonnell; Christian Trieflinger; Werner Temme; Grzegorz Gomulka; Michael Melchart; Burkhard Walther
- Web page: https://patentgrep.com/patent/US8785539B2

## CPC

- C04B 28/26: Silicates of the alkali metals
- C08G 18/10: Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
- C08G 18/4825: {Polyethers containing two hydroxy groups (C08G18/4833 - C08G18/5096 take precedence)}
- C04B 2111/28: Fire resistance, i.e. materials resistant to accidental fires or high temperatures
- C08G 2110/0066: ≥ 150kg/m3
- Y02W 30/91: Use of waste materials as fillers for mortars or concrete
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## Abstract

The present invention provides siliceous-based polyurea compositions, obtainable by reacting isocyanates, alkali silicates and hydratable aluminosilicates. Moreover, the present invention provides a process for the manufacture of these compositions, comprising the steps of mixing a hydratable aluminosilicate with an aqueous silicate and reacting this mixture with a polyisocyanate and/or a polyisocyanate prepolymer, optionally in the presence of a polyol and/or with the inclusion of an inert filler. Finally, the present invention provides the use of these compositions in the fields of aviation, automotive assemblies, construction, consumer products, fire protection, furniture components, insulation, shipbuilding and/or windmill construction. The compositions obtainable according to the present invention are lightweight, high load bearing, flame retarding materials.

## Claims

### Claim 1

A siliceous-based polyurea composition, obtained by reacting ingredients comprising
a) a polyisocyanate,
b) an aqueous silicate,
c) a hydratable aluminosilicate selected from metakaolin, fly ash, or mixtures thereof,
d) a polyol, and optionally
e) an inert filler.

### Claim 2 (depends on 1)

The composition of claim 1, the reaction ingredients comprising
20-65% by weight polyisocyanate,
5-55% by weight aqueous silicate,
2-20% by weight hydratable aluminosilicate selected from metakaolin, fly ash, or mixtures thereof,
up to 40% by weight polyol,
0-40% by weight inert filler.

### Claim 3 (depends on 1)

The composition of claim 1, wherein the polyisocyanate is an aliphatic isocyanate, an aromatic isocyanate or a combined aliphatic/aromatic isocyanate, having an —NCO functionality of ≧2.

### Claim 4 (depends on 1)

The composition of claim 1, wherein the aqueous silicate is an alkali silicate or ammonium silicate, having a modulus as defined by its SiO2:M2O molar ratio of 4.0-0.2, wherein M stands for a monovalent cation, and having a solids content of 10-70% by weight.

### Claim 5 (depends on 1)

The composition of claim 1, wherein the polyol is a polyfunctional alcohol having an —OH functionality of ≧2.

### Claim 6 (depends on 1)

The composition of claim 1, wherein at least a part of the polyisocyanate and polyol have been first reacted to form a polyisocyanate prepolymer having an —NCO functionality of ≧2.

### Claim 7 (depends on 1)

The composition of claim 1, wherein no halogenated and/or phosphorous-containing additives are comprised by the reaction ingredients.

### Claim 8 (depends on 1)

The composition of claim 1, wherein no foam stabilizing agents, catalysts and/or foaming agents are comprised by the reaction ingredients.

### Claim 9 (depends on 1)

A process for the manufacture of the composition as defined in claim 1, comprising the steps of mixing a hydratable aluminosilicate selected from metakaolin, fly ash, or mixtures thereof with an aqueous silicate and reacting this mixture with a polyisocyanate and/or a polyisocyanate prepolymer, optionally in the presence of a polyol and/or with the inclusion of an inert filler.

### Claim 10 (depends on 9)

The process of claim 9, further comprising controlled pressure release of gas formed in the reaction of the polyisocyanate and/or polyisocyanate prepolymer with water.

### Claim 11 (depends on 4)

The composition of claim 4, wherein the aqueous silicate is an alkali silicate or ammonium silicate, having a modulus as defined by its SiO2:M2O molar ratio of 4.0-1.0, wherein M stands for a monovalent cation.

### Claim 12 (depends on 4)

The composition of claim 4, wherein the aqueous silicate is an alkali silicate or ammonium silicate, having a solids content of 30-55% by weight.

### Claim 13 (depends on 1)

The composition of claim 1, wherein the aqueous silicate is ammonium, lithium, sodium or potassium waterglass.